Applicator for applying and distributing substances to target surfaces

ABSTRACT

Applicator for applying and distributing a substance onto a target surface. The applicator comprises a substantially planar sheet of compressible, conformable material having opposed first and second surfaces and an interior region between said first and second surfaces. The sheet of material has a thickness between the first and second surfaces which decreases when the sheet of material is subjected to an externally-applied force in a direction substantially normal to the first surface. The applicator further includes at least one discrete reservoir extending inwardly of the first surface into the interior of the sheet of material which is at least partially filled with a substance and at least one discrete aperture formed in the first surface which is in fluid communication with the reservoir. Compression of the sheet of material via an externally-applied force substantially normal to said first surface expresses product from the aperture and translational motion of the first surface relative to a target surface applies and distributes said product onto the target surface. In a preferred embodiment, a plurality of apertures are associated with corresponding reservoirs forming a delivery zone near one end of a hand-held applicator, and the sheet material is preferably resilient both in compression and in bending to conform to irregular target surfaces. A wide variety of substances are contemplated, including particularly antiperspirant/deodorant products. Other embodiments include a single reservoir feeding a plurality of apertures.

FIELD OF THE INVENTION

The present invention relates to applicators for use in manuallyapplying coatings of a substance onto a desired target surface. Moreparticularly, the present invention relates to such applicators whichprovide both dispensing and distribution functionality and thereforeenhanced product performance.

BACKGROUND OF THE INVENTION

There are many types of topical products that are commercially availableand/or commonly applied to a desired (target) surface in the form of athin film or coating to protect, treat, modify, etc. the target surface.Such products include those in the skin care, cosmetics, pharmaceutical,and other personal care arenas. One common example of such a product isthe antiperspirantldeodorant type of product, many of which areformulated as sprays, roll-on liquids, gels, creams, or solid sticks,and comprise an astringent material, e.g. zirconium or aluminum salts,incorporated into a suitable topical carrier. These products aredesigned to provide effective perspiration and odor control while alsobeing cosmetically acceptable during and after application onto theaxillary area or other areas of the skin.

Examples of suitable perforated caps or other shear force delivery meansfor use with such packaged compositions include those known in the artfor application of creams, or those delivery means that are otherwiseeffective for delivering the composition of the present invention to theskin, with the resulting rheology of the extruded product preferablyfalling within the ranges described hereinabove for extrudedcompositions. Some examples of such perforated caps or other shear forcedelivery means, and some dispensing packages for use with compositionsherein, are described in U.S. Pat. No. 5,000,356, issued to Johnson etal. on Mar. 19, 1991, which description is incorporated herein byreference.

While such delivery means have proven successful in applying suchsubstances, in many instances a comparatively complex supply mechanismis required in order to dispense the product for application by shearforce delivery means. This in turn typically requires a comparativelylarge canister to house not only the desired quantity of product butalso the product retention and supply mechanism as well. Economicfactors also typically require even travel size canisters for bothelevator-type and push-up-stick packages to have considerable weight andoccupy considerable volume, thus limiting the ability of the consumer toreadily transport such devices. Moreover, such constructions for allpractical considerations preclude the carrying of such devices on one'sperson such as in a pocket or modest-sized purse for replenishment ofone's antiperspirant or deodorant during the course of an extended stayaway from home.

Accordingly, it would be desirable to provide a discrete, convenienthand-held applicator for applying substances to target surfaces.

It would also be desirable to provide such an applicator which providesfor a substantially uniform coating of such substances to yield enhancedproduct performance.

It would also be desirable to provide such an applicator which is easyto use and may be economically produced.

SUMMARY OF THE INVENTION

The present invention provides an applicator for applying anddistributing a substance onto a target surface. The applicator comprisesa substantially planar sheet of compressible, conformable materialhaving opposed first and second surfaces and an interior region betweensaid first and second surfaces. The sheet of material has a thicknessbetween the first and second surfaces which decreases when the sheet ofmaterial is subjected to an extemally-applied force in a directionsubstantially normal to the first surface. The applicator furtherincludes at least one discrete reservoir extending inwardly of the firstsurface into the interior of the sheet of material which is at leastpartially filled with a substance and at least one discrete apertureformed in the first surface which is in fluid communication with thereservoir. Compression of the sheet of material via anexternally-applied force substantially normal to said first surfaceexpresses product from the aperture and translational motion of thefirst surface relative to a target surface applies and distributes saidproduct onto the target surface. In a preferred embodiment, a pluralityof apertures are associated with corresponding reservoirs forming adelivery zone near one end of a hand-held applicator, and the sheetmaterial is preferably resilient both in compression and in bending toconform to irregular target surfaces. A wide variety of substances arecontemplated, including particularly antiperspirant/deodorant products.Other embodiments include a single reservoir feeding multiple apertures.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim the present invention, it is believed that thepresent invention will be better understood from the followingdescription of preferred embodiments, taken in conjunction with theaccompanying drawings, in which like reference numerals identify likeelements and wherein:

FIG. 1 is a plan view of a preferred embodiment of an applicator inaccordance with the present invention;

FIG. 2 is an elevational sectional view of the applicator of FIG. 1taken along section line 2—2;

FIG. 3 is a schematical illustration of the applicator of FIGS. 1 and 2being utilized to manually apply a coating of a substance to a targetsurface;

FIG. 4 is a plan view similar to FIG. 1 of another embodiment of anapplicator; and

FIG. 5 is an elevational sectional view similar to FIG. 2 of theapplicator of FIG. 4 taken along section line 5—5.

FIG. 6 is a plan view of another preferred embodiment of an applicatorin accordance with the present invention;

FIG. 7 is a plan view of another preferred embodiment of an applicatorin accordance with the present invention; and

FIG. 8 is a plan view of another preferred embodiment of an applicatorin accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

1. Applicator Construction.

FIG. 1 depicts a preferred embodiment of an applicator 10 in accordancewith the present invention. Applicator 10 comprises a substantiallyplanar sheet of material 20 having a first side 21 and a second side 22,with the first and second sides defming an interior region 23 of thematerial 20. The first side 21 includes at least one aperture 30, andpreferably a plurality of apertures 30 forming a delivery zone 31. Thedelivery zone 31 encompasses not only the apertures 30 but also theinterstitial spaces 32 between adjacent apertures 30. As will beexplained hereafter, the presence and construction of the interstitialspaces 32 are believed to play an important role in the distributionperformance of the applicator 10 and in turn the performance of thesubstance distributed. In the embodiment shown in FIG. 1, the applicator10 also includes an optional cover 40 releasably affixed to first side21 so as to sealingly engage the first surface over and around theapertures 30 to occlude the apertures 30 and prevent prematuredispensing or contamination of the product before the intended use. Thecover may engage the first surface around the periphery of individualapertures or around the periphery of the delivery zone 31. Optionalcover 40 may comprise a label with instructions or other suitableindicia thereon.

Second side 22 is preferably free of apertures and is preferablysubstantially planar, although for some applications it may be desirableto include some surface topography (such as a series of smallprotrusions coinciding with the locations of reservoirs 50) at least inthe region underlying the delivery zone 31, to aid the user in orientingthe applicator properly. The first surface also preferably includes aoptional grasping portion 24 which is substantially free of aperturesand is preferably located adjacent to one edge of the applicator. Forsome application configurations, it may be desirable to include a seconddelivery zone remotely from the first delivery zone, either elsewhere onthe first surface or on the second surface of the applicator.

As shown more clearly in FIG. 2, the apertures 30 each extend inwardlyof the first surface 21 into the interior 23 of the sheet of material 20to form corresponding reservoirs 50 to contain a substance 60 prior touse. Suitable substances for use with the applicators of the presentinvention will be described in greater detail hereafter. Multiplesubstances may be employed in separate apertures and/or reservoirs, suchthat they remain segregated prior to applicator use but are co-mingledduring use. This may be particularly useful wherein it is desired toprevent reactions between components prior to use and correspondingdegradation or exhaustion of the active ingredients. Also, it may bedesirable to include one or more “empty” apertures/reservoirs to eitheradd air to the dispensed product and/or to act as a receiving reservoirto remove excess product from the target surface.

FIG. 2 also illustrates the geometrical relationship between theapertures 30, reservoirs 50, interstitial spaces 32, and the sheetmaterial 20. The apertures, which may be of any desired size and shape,each have a peripheral edge which lies in the plane of the first surface21 and defines the boundary of the aperture. In the instance where thesheet of material comprises a cellular structure, the apertures aresubstantially larger than the average cell size of the material. Theinterstitial spaces 32 are thus defmed as the portion of the firstsurface 21 located between the peripheral edges of adjacent apertures.The reservoirs are located inwardly of the apertures and comprises avoid within the interior of the sheet material. As with the apertures,the reservoirs are substantially larger than the average cell size ofthe material when the sheet of material is formed from a cellularstructure. The reservoirs may or may not have the same cross-sectionalshape in a direction parallel to the first surface 21 as that of theapertures 30. The sheet of material has an overall thickness T which isdefined as the average distance between the opposing first and secondsurfaces 21 and 22 measured in a direction substantially normal to thefirst surface. In the instance wherein the surfaces are parallel, thethickness T is perpendicular to both surfaces, and where non-planarsurfaces are involved the planes of respective surfaces are defined asan average position of a representative plane passing through thesurface topography.

The use of one or more discrete reservoirs as opposed to a generallyporous substance-impregnated material, provides a more controlled dosingfunctionality for the applicators of the present invention. Thereservoir geometry and volume may be designed as desired for ultimatecapacity and also rate of delivery, whether in the preferred pre-loadedconfiguration where the applicator is manufactured and sold with theproduct included or where the applicator is manufactured independentlyof the product and the consumer applies the substance to the applicator.

In a given applicator, the delivery zone may include a plurality ofapertures having differing sizes and/or shapes in either a regularpattern or an irregular pattern, and reservoirs need not also be filledto the same level or have the same capacity. Apertures can be of anydesired cross-sectional shape at their intersection with the firstsurface, such as oval, elliptical, hexagonal, etc, but a circularcross-sectional shape is presently preferred.

The reservoirs 50 extend inwardly from the first surface to a depth t.Accordingly, since the reservoirs are formed as voids in the sheet ofmaterial 20, the material is a comparatively thick material on the orderof at least about 0.063-0.250 inches as compared to forming reservoirsin thin embossed materials such as polymeric films. The sheet ofmaterial 20 is formed from a material which is sufficiently conformableto enable the first surface 21 to conform to irregular target surfaces,and is preferably resiliently conformable for application in a dynamicenvironment as the first surface passes over non-planar and irregularsurfaces. The material utilized for the applicator is also deformable inthe direction of thickness T to supply and deliver the substance 60 tothe target surface for application and distribution. Deformation of thesheet of material 20 in such a manner effectively reduces the volume ofthe reservoirs 50 in the region of deformation, thus expressing thesubstance from the reservoirs outwardly through the apertures 30 intocontact with the target surface.

Compressive deformation in the context of the present invention, asdescribed herein, is defined as a reduction in the dimension T of thematerial by application of an external force (or otherwise) such thatthe first and second surfaces become closer together and the interiordimension between them becomes smaller. This is to be distinguished fromother types of deformable structures wherein surfaces of the material orstructure are translated or rotated relative to each other to reduce theeffective thickness of the material. Such a thickness may be moreappropriately characterized as “caliper” rather than “thickness”, as the“caliper” of such a material will be by definition greater than the“thickness” of the material from which it is made. An example of such astructure would be a three-dimensionally-embossed film which has aplurality of dimples or ribs formed therein. The film initially has acertain thickness or gauge, but after deformation out of the plane ofthe material the film has a caliper increase due to the dimensions ofthe ribs or dimples. Such a material may undergo a dimensional reductionin a plane normal to the plane of the material, but only via thedeformation or destruction of the out-of-plane surfaces and structures.In structures and materials of the present invention, the caliper andthickness are substantially equivalent dimensions as any deviations fromsurface planarity in the vicinity of the delivery zone areinsignificant. Accordingly, as the material itself compresses under theinfluence of an external force the first and second surfaces move towardone another without rotating or otherwise distorting the geometry of thesheet material.

Without wishing to be bound by theory, it is believed that the use of acomparatively thick substantially planar material with reservoirs formedinto the material rather than the use of a comparatively thin materialwhich is formed into a non-planar structure provides an applicator whichallows application forces to be more uniformly transferred to the targetsurface for a more uniform substance distribution. This is particularlyimportant when the applied forces may be more discretely applied, suchas by one or more fingers spaced apart, as for most scenarios it isdesired to not have the resulting product distribution mirror thepattern of the applied forces. For example; if one holds the applicatorpad as shown in FIG. 3 it is desired to form a substantially uniformcoating of the substance upon the target surface rather than fourstreaks of product corresponding to the location of the four fingers.

Another important characteristic for applicators of the presentinvention is the ability of the material to “glide” across the targetsurface without rolling up or otherwise becoming distorted. This alsohelps to ensure a comparatively even substance distribution on thetarget surface. Accordingly, selection of suitable applicator materialsshould account for not only the substance characteristics in terms ofshear and other properties, but also the coefficient of friction of thematerial and the target surface.

The sheet material 20 may be unitary in nature, constructed from asingle monolithic piece of material, or may comprise two or more layersor plies of material. In addition, it may be desirable to form theapertures and reservoirs in one layer of material, completelypenetrating the sheet of material, and then laminating another layer ofsimilar or diverse composition onto the second surface of the firstpiece of material to close the inward end of the reservoirs.

A presently preferred construction utilizes a polyethylene/EVA foam padwith multiple heat-embossed product reservoirs/apertures in one surface.However, a wide variety of other materials are contemplated as beingwithin the scope of the present invention having suitable physicaland/or chemical properties for the intended substance and intendedtarget surface. The foam pad may be cut to the desired shape with apress and rule die, or other suitable means. The substance may beinjected, doctored, or otherwise supplied to the reservoirs. Theapplicator may be of any desired size and shape, although the shapedepicted in FIGS. 1-3 in dimensions of approximately 2.7″×2.4″×0.125″thick has proven satisfactory in use, with 38 equally sized and spacedreservoirs forming an ellipse having an approximate major dimension ofabout 1.5 to 2.0 inches and a minor dimension of about 0.9 to 1.3 inchesand delivering approximately 0.4 grams of antiperspirant composition(such as that described below). A presently preferred aperture size isbetween about 0.100 and about 0.150 inches in diameter, with a circularcross-section, an edge-to-edge spacing of between about 0.050 and about0.110 inches, with a substantially straight-walled reservoir of similarcross-section extending inwardly therefrom.

FIG. 6 depicts another embodiment of the present invention in the formof an applicator 200 having dimensions of approximately 2.7″×2.4″×0.125″thick, which has proven satisfactory in use. Applicator 200 has 8equally sized and spaced slot type reservoirs 210 positioned diagonallyat 45° within an ellipse area 220 having an approximate major dimensionof about 1.5 to 2.0 inches and a minor dimension of about 0.9 to 1.3inches and delivering approximately 0.4 grams of antiperspirantcomposition (such as that described below). A presently preferred slottype reservoir 210 for applicator 200 has a length between about 0.578and about 0.473 inches, a width between about 0.100 and about 0.080inches, with a slot type cross-section with rounded ends, anedge-to-edge spacing between reservoirs 210 of between about 0.220 andabout 0.080 inches, with a substantially straight-walled reservoir ofsimilar cross-section extending inwardly therefrom between about 0.125and about 0.080 inches in depth.

FIG. 7 depicts another embodiment of the present invention in the formof an applicator 300 having dimensions of approximately 2.7″×2.4″×0.125″thick, which has proven satisfactory in use. Applicator 300 has 9aperture-channel type reservoirs of varying configuration positionedwithin an ellipse area 360 having an approximate major dimension ofabout 1.5 to 2.0 inches and a minor dimension of about 0.9 to 1.3 inchesand delivering approximately 0.4 grams of antiperspirant composition(such as that described below). Applicator 300 has a variation of:2-aperture-channel reservoirs 310 having two apertures 340 connected bya single channel 350, 3-aperture-channel reservoirs 320 having threeapertures 340 connected by two channels 350, and 4-aperture-channelreservoirs 330 having four apertures 340 connected by three channels350. A presently preferred aperture 340 is between about 0.165 and about0.135 inches in diameter, with a circular cross-section. A presentlypreferred channel 350 is between about 0.055 and about 0.045 inches inwidth, with a rectangular cross-section. A presently preferred spacingbetween the center of adjoining apertures 340 is between about 0.280 andabout 0.200 inches in length. Edge-to-edge spacing between the apertures340 is between about 0.095 and about 0.065 inches. Reservoirs aresubstantially straight-walled of similar cross-section extendinginwardly therefrom between about 0.125 and about 0.080 inches in depth.

FIG. 8 depicts another embodiment of the present invention in the formof an applicator 400 having dimensions of approximately 2.7″×2.4″×0.125″thick, which has proven satisfactory in use. Applicator 400 has 7aperture-channel type reservoirs of varying configuration positioneddiagonally at 45° within an ellipse area having an approximate majordimension of about 1.5 to 2.0 inches and a minor dimension of about 0.9to 1.3 inches and delivering approximately 0.4 grams of antiperspirantcomposition (such as that described below). Applicator 400 has avariation of: 3-aperture-channel reservoirs 410 having three apertures440 connected by two channels 450, 4-aperture-channel reservoirs 420having four apertures 440 connected by three channels 450, and5-aperture-channel reservoirs 430 having five apertures 440 connected byfour channels 450. A presently preferred aperture 440 is between about0.165 and about 0.135 inches in diameter, with a circular cross-section.A presently preferred channel 450 is between about 0.055 and about 0.045inches in width, with a rectangular cross-section. A presently preferredspacing between the center of adjoining apertures 440 is between about0.280 and about 0.200 inches in length. Edge-to-edge spacing between theapertures 440 is between about 0.095 and about 0.065 inches. Reservoirsare substantially straight-walled of similar cross-section extendinginwardly therefrom between about 0.125 and about 0.080 inches in depth.

For a given product, an applicator design should be optimized tominimize premature dispensing and to maximize intentional-delivery ofthe desired product. A method which is believed to prevent prematuredispensing of the desired product is to maximize the surface area of thereservoirs to which the product will adhere. The product typically hasan affinity to the applicator surface; therefore, the product has atendency to remain within the reservoirs. However, increasing thesurface area of the reservoirs also decreases the amount of product thatwill be delivered intentionally later by the consumer. The propensity ofthe product to stay in the reservoir due to reservoir surface area, andthe corresponding propensity of the product to be intentionallydelivered by the consumer, are inversely related but not necessarilylinearly proportional. Without wishing to be bound by theory, it isbelieved that as the surface area of a reservoir is increased for aconstant reservoir volume and depth, there results a reduction inpremature dispensing but also a corresponding, but not necessarilylinearly, proportional reduction in intentionally-delivered product.Such theory may be discussed in reference to an aspect ratio defined andcalculated as the [surface area of the reservoir]/[surface area of acylindrical reservoir having an equal volume and depth]. It is believedthat as the aspect ratio is increased, there results a reduction inpremature dispensing but also a corresponding, but not necessarilylinearly, proportional reduction in intentionally-delivered product. Indetermining the optimal applicator design for a given product, thisaspect ratio may be used to compare various designs. For the embodimentsillustrated in FIGS. 6, 7, and 8 such a method of optimization wasutilized and it was found that an aspect ratio ranging from about 1 toabout 5 has proven satisfactory in use for the products describedherein.

As mentioned previously, it is presently preferred that the materialsutilized in the present invention are not only compressible in thethickness direction but also conformable in the planar direction so asto accommodate various target surface topographies in use. It is alsopreferred that suitable sheet materials also be resilient, preferablyboth in terms of their compressibility and in terms of their bendingconformability. Resilience is defined consistent with its everydaymeaning, as evidenced by Webster's Ninth New Collegiate Dictionary, as“the capability of a strained body to recover its size and shape afterdeformation caused esp. by compressive stress.” Resilience of thematerial causes it to tend to return to its undeformed, preferablysubstantially planar state and original thickness after compressive orbending forces, thereby enabling it to conform to various targetsurfaces and yet maintain target surface contact for proper substancedistribution.

Preferred material properties, as well as the properties of thepresently preferred material, Volara 2E0 ⅛″ PE/EVA polyethylene/ethylenevinyl acetate copolymer (12%VA) fine-cell crosslinked polymer foam,commercially available from Voltek, 100 Shepard Street, Lawrence, Mass.01843, are presented in the table below:

Preferred PROPERTIES Volara 2E0 ⅛″ Range Test Method Thickness in. 0.1250.063-0.250 ASTM D-3575 Density lbs/cu ft. 2 nominal 2-6 ASTM D-3575Tensile Str psi (MD) 55 min.  40-200 ASTM D-3575 Break Elongation 140min. 100-350 ASTM D-3575 % (MD) Tear Resistance 7 min. 4.5-30  ASTMD-3575 lb/in (MD) Compression Str. Psi @25% deflection 2.5 min. 1.5-15 ASTM D-3575 @50% deflection 9 min.  4-25 ASTM D-3575 Compression set %30 max.  0-50 ASTM D-3575

To quantify stiffniess, a suitable method is TAPPI T489 om-92, Stiffiessof paper and paperboard (Taber-type stiffness tester). Results are ingram centimeters or Taber units. Equipment used; Taber V-5 model 150BStifffiess Tester. Note: NO weight added and results measured at 15degrees displacement.

Actual Data: Material ⅛″ caliper (Voltek #) MD CD polyethylene (2A) 65gm cm  2 PE/EVA 12% VA (2EO) 47 34 PE/EVA 18% VA (2G) 41 32

Preferred limit range for ⅛″ thick, 2PCF foam are: MD testing=75-35 gramcentimeters, CD testing=50-25 gram centimeters

While Volara 2EO is presently preferred material, alternate Volaragrades and alternate foam materials such as open cell foam,non-crosslinked foam, foam with a range of cell sizes, alternate resins,100% polyethylene, polystyrene, polypropylene, rubber, urethanes, otherethylene copolymers, propylene copolymers, and other synthetic materialshaving similar material properties could be used. Note, however, forsome applications materials being substantially stiffer or softer may bepreferred.

In the embodiment shown in FIGS. 1 and 2, the reservoirs have wallswhich are substantially normal to the first surface of the sheet ofmaterial. However, for certain product formulations of the substance tobe delivered to the target surface it may be desirable to providereservoir and aperture geometries wherein the reservoirs have sidewallsat angles other than 90 degrees, such as, for example, fuinnel-shapedtapered aperture/reservoir geometries wherein the reservoir narrows withincreasing distance inwardly from the first surface or “undercut”aperture geometries where the reservoir widens with increasing distanceinwardly from the first surface. Reservoirs may also be formed withsubstantially planar bottoms (the portion located distally from theapertures and within the interior of the sheet of material), or thebottoms of the reservoirs may be radiused, depending upon themanufacturing method of choice and the nature of the substances andsheet materials employed.

In addition, it is preferred that when the sheet of material comprises aporous material the reservoirs include some suitable means of preventingsubstance migration into the matrix of the sheet material. A presentlypreferred method of preventing such migration is to utilize aclosed-cell foam material. However, such means may include animpermeable coating or may be some other means of rendering thereservoir walls impermeable such as thermally melting the porous sheetmaterial during formation of the apertures and reservoirs to form a“skin”. Additional layers or coatings of polymers such as PET, nylon,etc. may be employed on the reservoir walls, the second side 21 of theapplicator, or other regions where it is desired to limit substancepenetration of the material. Any such treatments or approaches would betailored to suit the particular combination of substance and applicatormaterial(s). For some applications, it may also be desirable that theinner surfaces of the reservoir(s) and aperture(s) have some degree ofsurface topography to aid in anchoring the substance. Internalstructures such as protrusions, “bosses”, peripheral rings, etc., mayalso be desirable to aid in substance retention. Various reservoirconfigurations may be employed without being limited to the apertureshape or the overall shape of the applicator, and may be tailored asdesired to facilitate substance retention and/or dispensing.

FIG. 3 provides an illustration of an applicator 10 in accordance withthe present invention being utilized to apply a substance to a targetsurface. As shown in FIG. 3, the applicator 10 is manually grasped bythe hand 80 of a user, typically by pinching the applicator between thethumb and palm with the fmgers contacting the second surface 22 in thevicinity of apertures 30 and the thumb contacting the grasping portion24. The user then brings the delivery zone 31 of the applicator 10 intocontact with a target surface 90, which may have any surface topographyand may be planar or non-planar, and applies a force having at least anormal force vector component in a direction F which is substantiallynormal to the target surface 90. A tangential force or force vectorcomponent exerted in direction D is applied, preferably simultaneouslywith the application of normal force F, to move the applicator acrossthe target surface 90 to apply a substantially uniform coating of thesubstance 60 to the target surface, preferably in a region substantiallyconforming to the scope of the delivery zone 31 and to the distancetravelled. The normal and tangential forces may combine in such a manneras to define a total force vector which defines an angle between about 0and about 90 degrees from the plane of the first surface. Such a mannerof application provides for dispensing of the substance during thedistribution phase of the process, rather than the typical extrusion ordispensing of substances followed by the distribution phase.

In a dynamic application environment such as that depicted in FIG. 3, incontrast with a “static” application scenario with no relativetranslational movement, it is believed that the relationship between theapertures (where a plurality are utilized) and the spaces between themis an important consideration in the design of suitable applicatorgeometries for particular substances. Each aperture has a peripheraledge which is surrounded by a portion of the first surface of the sheetmaterial. As the sheet material, at least the first surface thereof, ispreferably substantially planar, each aperture is thus surrounded by asubstantially planar ring of material which contacts the target surfacearound the aperture and which provides a “rub-in” surface to distributethe substance on the target surface. Where the substance is or becomesflowable at the time of application, this ring of material forms agasket-like surface which aids in uniformly distributing product byencouraging the outward flow of product from the apertures. Optionally,if desired a certain amount of surface texture, such as microtexture,may be applied to the portions of the first surface between and/oradjacent to the apertures to aid in the distribution function and/or theaesthetics of the application function in terms of skin feel, etc.

The applicators of the present invention depicted in FIGS. 1-3 havecorresponding plural apertures and plural reservoirs, and preferably a1:1 ratio of apertures to reservoirs. However, other combinations ofapertures and reservoirs are also possible, such as multiple reservoirssupplying each aperture or multiple apertures supplied by a singlereservoir. FIGS. 4 and 5 depict such an alternate embodiment. Theapplicator 110 of FIGS. 4 and 5 has a sheet of material 120 similar tothe sheet of material 20 of FIGS. 1-3, but unlike the applicator 10 theapplicator 110 has a plurality of apertures 130 which extend inwardlyfrom the first surface 121 through the interior 123 of the sheet ofmaterial all the way through the second side 122, such that a completelyunobstructed passageway is provided through the sheet of material 120.In such an embodiment, the sheet of material has a thickness T which isequivalent to the distance t (omitted for clarity). The apertures 130form a delivery zone 131, are separated by interstitial spaces 132, andare preferably but optionally covered by a removable cover 140 which mayhave instructions or other suitable indicia thereon. The applicator 110also includes a backing sheet 170 which is peripherally joined to thesheet of material 120 via a heat seal 125 or other suitable sealingtechnique, the backing sheet 170 cooperating with the seal 125, sheet ofmaterial 120, and cover 140 to form at least one, and preferably onlyone, reservoir 150 for containing a product 160 therein.

Another variation would include the use of a single large reservoir inan embodiment similar to that of FIG. 1, but including a plurality of“islands” protruding from the floor of the reservoir to provide asurface-contacting rub-in surface analogous to the network ofinterstitial spaces formed between multiple discrete apertures as shownin FIG. 1.

The apertures of the applicators of the present invention may be sealedprior to use in other ways than the use of a cover/label such as cover40/140. For example, applicators may be sealed/bonded to one another inface-to-face or back-to-back relationship such that one surface of oneapplicator obstructs the apertures of the next. Other possibleorientations include face-to-face orientations with delivery zonesnon-aligned and overlying other portions of the first surface,face-to-back, etc., and pairs of such materials can be packaged in abarrier film (foil laminate, metallized polyester, etc.) to form aconvenient package.

The applicator of the present invention comprises a packaged deliverysystem having a shear force delivery means. Other examples of suchdelivery systems are well known in the art, and typically comprise anenclosed package or container having an attached shear force deliverymeans such as a perforated cap or other perforated surface. Shear forcedelivery means subject the delivered substance to shear forces whichcounteract the tendencies of the substance to agglomerate and/or remainin comparatively large or thick deposits and spread across the targetsurface. The application of shear force in combination with thesubstance delivery process is particularly important when the rheologyand other product characteristics change under the influence of shearforces, such as the substance becoming more flowable under shear.Additional discussion of substance rheology follows hereafter.

Typical shear force delivery means include any ridged or flexiblesurface, preferably a ridged surface, suitable for attachment to apackage or other product, and which has a plurality of openings,apertures or orifices extending through the thickness of the ridged orflexible surface through which the composition can flow to the intendedsite of application. However, in accordance with the present inventionthe applicators described herein provide delivery and distributionfunctionality meeting or exceeding that of other shear force deliverymeans in a convenient, economical, easy-to-use form.

2. Representative Compositions.

In the present invention, the term “substance” can mean a flowablesubstance which is substantially non-flowing prior to delivery to atarget surface. “Substance” can also mean a material which doesn't flowat all, such as a fibrous or other interlocking material. “Substance”may mean a fluid or a solid. “Substance” is defined in this invention asany material capable of being held in open three-dimensional recesses ofthe applicator material in the absence of external forces other thanthose of gravity. While substances which are substantially non-flowableprior to delivery are presently preferred, substances which are flowableor have greater flowability may be found suitable for use in the presentinvention wherein overwraps, seals, or the like provide for sufficientsubstance retention/protection prior to use. Adhesives, electrostatics,mechanical interlocking, capillary attraction, surface adsorption, vander Waals forces, and friction, for example, may be used to hold thesubstances in the apertures and/or reservoirs. The substances areintended to be at least partially released therefrom when exposed tocontact with external surfaces when the applicator is subjected toexternally-applied compressive forces. Of current interest in thepresent invention include substances such as gels, pastes, creams,lotions, foams, powders, agglomerated particles, prills,microencapsulated liquids, waxes, suspensions, liquids, and combinationsthereof.

The spaces in the three dimensional structure of the present inventionare normally open; therefore it is desirable to have substances stay inplace and not run out of the structure without an activation step.Accordingly, substances which are preferred are capable of stayingwithin the apertures and/or reservoirs even in the absence of anoverwrap. The activation step utilized in accordance with the presentinvention is deformation of the three dimensional structure bycompression, which overcomes the tendencies of the substance to remainwithin the applicator.

Preferred substances include those which may be liberated from theapplicator without the need for solvents (including water, etc.) inorder to provide for a ready-to-use device. However, such preferenceshould not preclude the use of otherwise suitable substances merelybecause some degree of solvent use may be necessary. Suitable substancesmay be anhydrous, and perform satisfactorily and desirably in theabsence of water.

Antiperspirant/Deodorant Compositions

The antiperspirant and deodorant substances for use in the applicator ofthe present invention are non-flowing compositions which are intendedfor topical application to the underarm or other suitable areas of theskin. These deodorant and antiperspirant compositions comprise an activeingredient and a suspending or thickening agent incorporated into asuitable liquid carrier. In this context, the term “active” refers toantiperspirant actives, deodorant actives, or fragrances, and includeany known or otherwise safe and effective antiperspirant, deodorant, orfragrance active material. The terms “antiperspirant active” and“deodorant active” specifically refers to topical materials which canprevent or eliminate malodors and/or perspiration wetness. The term“fragrance” as used herein specifically refers to any topical materialwhich covers or masks malodors resulting from perspiration, or whichotherwise provides the composition with the desired perfumed aroma.

Antiperspirant Active

The antiperspirant compositions for use in the applicator of the presentinvention comprise antiperspirant active suitable for application tohuman skin. The antiperspirant active may be solubilized in theantiperspirant compositions or may be suspended as an undissolved orprecipitated solid. The concentration of the antiperspirant active inthe antiperspirant compositions should be sufficient to provide thedesired odor and wetness control from the antiperspirant compositionselected.

The antiperspirant compositions described herein comprise antiperspirantactive at concentrations of from about 0.5% to about 60%, preferablyfrom about 0.5% to about 50%, more preferably from about 5% to about35%, by weight of the selected antiperspirant composition. All suchweight percentages are calculated on an anhydrous metal salt basisexclusive of water and any complexing agents such as glycine, glycinesalts, or other complexing agents.

The antiperspirant active for use in the antiperspirant compositionsdescribed herein include any compound, composition or other materialhaving antiperspirant activity. Preferred antiperspirant actives includethe astringent metallic salts, especially the inorganic and organicsalts of aluminum, zirconium and zinc, as well as mixtures thereof.Particularly preferred are the aluminum and zirconium salts, such asaluminum halides, aluminum hydroxyhalides, zirconyl oxyhalides, zirconylhydroxyhalides, and mixtures thereof.

Preferred aluminum salts for use in the antiperspirant compositionsinclude those which conform to the formula:

Al₂(OH)_(a) Cl_(b)·x H₂O

wherein a is from about 2 to about 5; the sum of a and b is about 6; xis from about 1 to about 6; and wherein a, b, and x may have non-integervalues. Particularly preferred are the aluminum chlorhydroxides referredto as “⅚ basic chlorhydroxide”, wherein a=5, and “⅔ basicchlorhydroxide”, wherein a=4. Processes for preparing aluminum salts aredisclosed in U.S. Pat. No. 3,887,692, Gilman, issued Jun. 3, 1975; U.S.Pat. No. 3,904,741, Jones et al., issued Sep. 9, 1975; U.S. Pat. No.4,359,456, Gosling et al., issued Nov. 16, 1982; and British PatentSpecification 2,048,229, Fitzgerald et al., published Dec. 10, 1980,which disclosures are incorporated herein by reference. Mixtures ofaluminum salts are described in British Patent Specification 1,347,950,Shin et al., published Feb. 27, 1974, which description is alsoincorporated herein by reference.

Preferred zirconium salts for use in the antiperspirant compositionsinclude those which conform to the formula:

ZrO(OH)_(2−a)Cl_(a)·x H₂O

wherein a is any number having a value of from about 0 to about 2; x isfrom about 1 to about 7; and wherein a and x may both have non-integervalues. These zirconium salts are described in Belgian Patent 825,146,Schmitz, issued Aug. 4, 1975, which description is incorporated hereinby reference. Particularly preferred zirconium salts are those complexeswhich additionally contain aluminum and glycine, commonly known as ZAGcomplexes. These ZAG complexes contain aluminum chlorhydroxide andzirconyl hydroxy chloride conforming to the above described formulas.Such ZAG complexes are described in U.S. Pat. No. 3,679,068, Luedders etal., issued Feb. 12, 1974; Great Britain Patent Application 2,144,992,Callaghan et al., published Mar. 20, 1985; and U.S. Pat. No. 4,120,948,Shelton, issued Oct. 17, 1978, which descriptions are incorporatedherein by reference.

The antiperspirant active may be formulated as particulate solids in theform of dispersed solid particles having a preferred average particlesize or diameter of less than about 100 μm, more preferably from about 2μm to about 50 μm, even more preferably from about 0.4 μm to about 40μm.

The antiperspirant compositions described herein may comprisesolubilized antiperspirant active, preferably solubilized antiperspirantactive in an anhydrous system. The concentration of solubilizedantiperspirant active in the antiperspirant compositions preferablyranges from about 0.1% to 35%, more preferably from about 0.5% to about25%, even more preferably from about 1% to about 17%, even morepreferably from about 6% to about 17%, by weight of the selectedantiperspirant composition (weight percentages calculated on ananhydrous metal salt basis exclusive of water and any complexing agentssuch as glycine, glycine salts, or other complexing agents).

Deodorant Active

The deodorant compositions for use in the applicator of the presentinvention comprise deodorant active at concentrations ranging from about0.001% to about 50%, preferably from about 0.01% to about 20%, morepreferably from about 0.1% to about 10%, even more preferably from about0.1% to about 5%, by weight of the selected deodorant composition. Thesedeodorant actives can include any known or otherwise safe and effectivedeodorant active suitable for topical application to human skin.

Deodorant actives suitable for use in the deodorant compositionsdescribed herein include any topical material that is known for or isotherwise effective in preventing or eliminating malodor associated withperspiration. These deodorant actives are typically antimicrobial agents(e.g., bacteriocides, fungicides), malodor-absorbing material, orcombinations thereof.

Preferred deodorant actives are antimicrobial agents, non-limitingexamples of which include cetyl-trimethylammonium bromide, cetylpyridinium chloride, benzethonium chloride, diisobutyl phenoxy ethoxyethyl dimethyl benzyl ammonium chloride, sodium N-lauryl sarcosine,sodium N-palmethyl sarcosine, lauroyl sarcosine, N-myristoyl glycine,potassium N-lauryl sarcosine, trimethyl ammonium chloride, sodiumaluminum chlorohydroxy lactate, triethyl citrate, tricetylmethylammonium chloride, 2,4,4′-trichlorio-2′-hydroxy diphenyl ether(triclosan), 3,4,4′-trichlorocarbanilide (triclocarban), diaminoalkylamides such as L-lysine hexadecyl amide, heavy metal salts of citrate,salicylate, and piroctose, especially zinc salts, and acids thereof,heavy metal salts of pyrithione, especially zinc pyrithione, zincphenolsulfate, farnesol, and combinations thereof.

Other deodorant actives include odor-absorbing materials such ascarbonate and bicarbonate salts, including alkali metal carbonates andbicarbonates, ammonium and tetraalkylammonium. Preferred are sodium andpotassium salts of such odor-absorbing materials.

Fragrance

Fragrances suitable for use herein include any topical material that isknown for or is otherwise effective in masking malodor associated withperspiration, or which otherwise provides the substance compositionswith the desired perfumed aroma. These fragrances include any perfume orperfume chemical suitable for topical application to the skin. Thefragrance material can be used alone or in combination with theantiperspirant active or deodorant active. Concentrations of thefragrance material generally range from about 0.001% to about 50%,preferably from about 0.01% to about 20%, more preferably from about0.1% to about 10%, even more preferably from about 0.1% to about 5%, byweight of the selected antiperspirant or deodorant composition.

The concentration of the fragrance in the antiperspirant or deodorantcompositions should be effective to provide the desired aromacharacteristics or to mask malodor, wherein the malodor is inherentlyassociated with the composition itself or is associated with malodordevelopment from human perspiration. Also, the fragrance and whatevercarriers accompany it should not impart excessive stinging to the skin,especially broken or irritated skin, at the levels previously disclosed.The fragrance will typically be in the form of water insoluble perfumesthat are solubilized in the antiperspirant or deodorant compositionsdescribed herein.

Fragrances are made by those skilled in the art in a wide variety offragrances and strengths. Typical fragrances are described in Arctander,Perfume and Flavour Chemicals (Aroma Chemicals), Vol. I and II (1969);and Arctander, Perfume and Flavour Materials of Natural Origin (1960).U.S. Pat. No. 4,322,308 and U.S. Pat. No. 4,304,679, both incorporatedherein by reference, disclose fragrance components as generallyincluding, but are not limited to, volatile phenolic substances (such asiso-amyl salicylate, benzyl salicylate, and thyme oil red); essence oils(such as geranium oil, patchouli oil, and petitgrain oil); citrus oils;extracts and resins (such as benzoin siam resinoid and opoponaxresinoid); “synthetic” oils (such as Bergamot 37 and 430, Geranium 76and Pomeransol 314); aldehydes and ketones (such as B-methyl naphthylketone, p-t-butyl-A-methyl hydrocinnamic aldehyde and p-t-amylcyclohexanone); polycyclic compounds (such as coumarin and β-naphthylmethyl ether); esters (such as diethyl phthalate, phenylethylphenylacetate, non-anolide-1:4). Fragrances also include esters andessential oils derived from floral materials and fruits, citrus oils,absolutes, aldehydes, resinoides, musk and other animal notes (e.g.,natural isolates of civet, castoreum and musk), balsamic, etc. andalcohols (such as dimyrcetol, phenylethyl alcohol and tetrahydromuguol).Examples of such components useful as fragrances herein include decylaldehyde, undecyl aldehyde, undecylenic aldehyde, lauric aldehyde, amylcinnamic aldehyde, ethyl methyl phenyl glycidate, methyl nonylacetaldehyde, myristic aldehyde, nonalactone, nonyl aldehyde, octylaldehyde, undecalactone, hexyl cinnamic aldehyde, benzaldehyde,vanillin, heliotropine, camphor, para-hydroxy phenolbutanone, 6-acetyl1,1,3,4,4,6 hexamethyl tetrahydronaphthalene, alpha-methyl ionone,gamma-methyl ionone, and amyl-cyclohexanone and mixtures of thesecomponents.

Other suitable fragrances are those which mask or help to mask odorsassociated with perspiration (hereinafter referred to as odor maskingfragrances), some non-limiting examples of which are described in U.S.Pat. No. 5,554,588, U.S. Pat. No. 4,278,658, U.S. Pat. No. 5,501,805,and EP Patent Application 684 037 A1, all of which are incorporatedherein by reference in their entirety. Preferred odor masking fragrancesare those which have a Deodorant Value of at least about 0.25, morepreferably from about 0.25 to about 3.5, even more preferably from about0.9 to about 3.5, as measured by the Deodorant Value Test described inEP Patent Application 684 037 A1.

The fragrance for use herein may also contain solubilizers, diluents, orsolvents which are well known in the art. Such materials are describedin Arctander, Perfume and Flavour Chemicals (Aroma Chemicals), Vol. Iand II (1969). These materials typically include small amounts ofdipropylene glycol, diethylene glycol, C₁-C₆ alcohols, and/or benzylalcohol.

Suspending or Thickening Agent

The antiperspirant and deodorant compositions for use in the applicatorof the present invention comprise a suspending or thickening agent tohelp provide the compositions with the desired viscosity or producthardness, or to otherwise help suspend any dispersed solids or liquidswithin the compositions. Suitable suspending or thickening agentsinclude any material known or otherwise effective in providingsuspending or thickening properties to the compositions, or whichotherwise provide structure to the fmal product forms. These suspendingor thickening agents include gelling agents, and polymeric ornonpolymeric or inorganic thickening or viscosifying agents. Suchmaterials will most typically include organic solids, silicone solids,crystalline or other gellants, inorganic particulates such as clays orsilicas, or combinations thereof.

The concentration and type of the suspending or thickening agentselected for use in the antiperspirant and deodorant compositions willvary depending upon the desired product form, viscosity, and hardness.For most suspending or thickening agents suitable for use in thecompositions described herein, the concentration of such suspending orthickening agents will most typically range from about 0.1% to about35%, more typically from about 0.1% to about 20%, by weight of theselected antiperspirant or deodorant composition.

Suitable gelling agents for use as suspending or thickening agentsherein include, but are not limited to, fatty alcohols, esters of fattyalcohols, fatty acids, hydroxy fatty acids, esters and amides of fattyacids or hydroxy fatty acids, ethers of fatty acids, ethoxylated fattyalcohols, ethoxylated fatty acids, waxes, cholesterolic materials,dibenzylidene alditols, lanolinolic materials, other amide and polyamidegellants, and corresponding salts thereof. All such gellants preferablyhave a fatty alkyl moiety having from about 14 to about 60 carbon atoms,more preferably from about 20 to about 40 carbon atoms, and which may besaturated or unsaturated, substituted or unsubstituted, branched orlinear or cyclic.

The term “substituted” as used herein refers to chemical moieties knownor otherwise effective for attachment to gellants or other compounds.Such substituents include those listed and described in C. Hansch and A.Leo, Substituent Constants for Correlation Analysis in Chemistry andBiology (1979), which listing and description are incorporated herein byreference. Examples of such substituents include, but are not limitedto, alkyl, alkenyl, alkoxy, hydroxy, oxo, nitro, amino, aminoalkyl(e.g., aminomethyl, etc.), cyano, halo, carboxy, alkoxyaceyl (e.g.,carboethoxy, etc.), thiol, aryl, cycloalkyl, heteroaryl,heterocycloalkyl (e.g., piperidinyl, morpholinyl, pyrrolidinyl, etc.),imino, thioxo, hydroxyalkyl, aryloxy, arylalkyl, and combinationsthereof.

The term “corresponding salts” as used herein refers to cationic saltsformed at any acidic (e.g., carboxyl) group, or anionic salts formed atany basic (e.g., amino) group, either of which are suitable for topicalapplication to human skin. Many such salts are known in the art,examples of which are described in World Patent Publication 87/05297,Johnston et al., published Sep. 11, 1987, which description isincorporated herein by reference.

Suitable fatty alcohols for use in the antiperspirant compositionsdescribed herein include those compounds that are solids under ambientconditions and that have from about 8 to about 40 carbon atoms. Thesegelling agents are wax-like materials which are most typically used atconcentrations ranging from about 0.1% to about 25%, preferably fromabout 3% to about 20%, by weight of the selected antiperspirantcomposition. Specific examples of fatty alcohols for use herein include,but are not limited to, cetyl alcohol, myristyl alcohol, stearylalcohol, and the Unilins available from Petrolite as Unilin 550, Unilin700, Unilin 400, Unilin 350, and Unilin 325.

Nonlimiting examples of suitable esters of fatty alcohols for use in theantiperspirant compositions described herein include tri-isostearylcitrate, ethyleneglycol di-12-hydroxystearate, tristearylcitrate,stearyl octanoate, stearyl heptanoate, trilaurylcitrate.

Suitable fatty acids for use in the antiperspirant and deodorantcompositions described herein include, but are not limited to, fattyacid and hydroxy or alpha hydroxy fatty acids having from about 10 toabout 40 carbon atoms, examples of which include 12-hydroxystearic acid,12-hydroxylauric acid, 16-hydroxyhexadecanoic acid, behenic acid, eurcicacid, stearic acid, caprylic acid, lauric acid, isostearic acid,combinations thereof, and salts thereof. Some preferred examples offatty acids suitable for use herein are disclosed in U.S. Pat. No.5,429,816, issued to Hofrichter et al. on Jul. 4, 1995; and U.S. Pat.No. 5,552,136, issued to Motley on Sep. 3, 1996, both disclosures ofwhich are incorporated by reference herein. Some commercial examples offatty acids include, but are not limited to, Unicid 400, available fromPetrolite.

Nonlimting examples of salts of fatty acids for use in theantiperspirant and deodorant compositions described herein include thosecompounds wherein the fatty acid moiety has from about 12 to about 40carbon atoms, preferably from about 12 to about 22 carbon atoms, morepreferably from about 16 to about 20 carbon atoms, most preferably about18 carbon atoms. Suitable salt forming cations for use with thesegelling agents include metal salts such as alkali metals, e.g. sodiumand potassium, and alkaline earth metals, e.g. magnesium, and aluminum.Preferred are sodium and potassium salts, more preferably sodiumstearate, sodium palmitate, potassium stearate, potassium palmitate,sodium myristate, aluminum monostearate, and combinations thereof. Mostpreferred is sodium stearate.

Suitable ethoxylated gellants for use in the antiperspirant compositionsdescribed herein include, but are not limited, Unithox 325, Unithox 400,Unithox 450, Unithox 480, Unithox 520, Unithox 550, Unithox 720, andUnithox 750 (all of which are available from Petrolite), C20 to C40pareth-3, and combinations thereof.

Suitable fatty acid esters for use in the antiperspirant compositionsdescribed herein include ester waxes, monoglycerides, diglycerides,triglycerides and combinations thereof. Preferred are the glycerideesters. Nonlimiting examples of suitable ester waxes including stearylstearate, stearyl behenate, palmityl stearate, stearyl octyldodecanol,cetyl esters, cetearyl behenate, behenyl behenate, ethylene glycoldistearate, ethylene glycol dipalmitate, and beeswax. Examples ofcommercial ester waxes include Kester waxes from Koster Keunen, CrodamolSS from Croda, and Demalcare SPS from Rhone Poulenc. Preferred areglyceryl tribehenate and other triglycerides, wherein at least about75%, preferably about 100%, of the esterified fatty acid moieties ofsaid other triglycerides each have from about 18 to about 36 carbonatoms, and wherein the molar ratio of glyceryl tribehenate to said othertriglycerides is from about 20:1 to about 1:1, preferably from about10:1 to about 3:1, more preferably from about 6:1 to about 4:1. Theesterified fatty acid moieties may be saturated or unsaturated,substituted or unsubstituted, linear or branched, but are preferablylinear, saturated, unsubstituted ester moieties derived from fatty acidmaterials having from about 18 to about 36 carbon atoms. Thetriglyceride gellant preferably has a preferred melting point of lessthan about 110° C., preferably between about 50° C. and 110° C.Preferred concentrations of the triglyceride gellants range from about4% to about 20%, more preferably from about 4% to about 10%, by weightof the selected antiperspirant composition. Specific examples ofpreferred triglyceride gellants include, but are not limited to,tristearin, hydrogenated vegetable oil, trihydroxysterin (Thixcin® R,available from Rheox, Inc.), rape seed oil, castor wax, fish oils,tripalmiten, Syncrowax® HRC and Syncrowax® HGL-C (Syncrowax® availablefrom Croda, Inc.). Other suitable glycerides include, but are notlimited to, glyceryl stearate and glyceryl distearate.

Suitable amide gellants for use in the antiperspirant and deodorantcompositions described herein include monoamide gellants, diamidegellants, triamide gellants, and combinations thereof, nonlimitingexamples of which include cocoamide MEA (monoethanolamide), stearamide,oleamide, oleamide MEA, tallow amid monoethanolamide, and the n-acylamino acid amide derivatives described in U.S. Pat. No. 5,429,816,issued to Hofrichter et al. on Jul. 4, 1995, which description isincorporated herein by reference. Other suitable amide gelling agentsare described in U.S. Pat. No. 5,429,816, and U.S. patent applicationSer. No. 08/771,183, filed Dec. 20, 1996, which descriptions areincorporated herein by reference. Concentrations of the amide gellantspreferably range from about 0.1% to about 25%, more preferably fromabout 1% to about 15%, even more preferably from about 1% to about 10%,by weight of the selected antiperspirant or deodorant composition.

Other suitable gelling agents for use in the antiperspirant anddeodorant compositions described herein include waxes or wax-likematerials having a melt point of above 65° C., more typically from about65° C. to about 130° C., examples of which include, but are not limitedto, waxes such as beeswax, camauba, baysberry, candelilla, montan,ozokerite, ceresin, hydrogenated castor oil (castor wax), syntheticwaxes, microcrystalline waxes. Castor wax is preferred within thisgroup. Other high melting point waxes are described in U.S. Pat. No.4,049,792, Elsnau, issued Sep. 20, 1977, which description isincorporated herein by reference.

Other suitable suspending or thickening agents for use in theantiperspirant compositions described herein include particulatesuspending or thickening agents such as clays and colloidal pyrogenicsilica pigments. Other known or otherwise effective particulatesuspending or thickening agents can likewise be used in the substancecompositions described herein. Concentrations of these suitableparticulate thickening agents preferably range from about 0.001% toabout 15%, more preferably from about 1% to about 15%, even morepreferably from about 1% to about 8%, by weight of the selectedantiperspirant composition. Colloidal pyrogenic silica pigments arepreferred, a common example of which includes Cab-O-Sil®, asubmicroscopic particulated pyrogenic silica.

Suitable clay suspending or thickening agents include montmorilloniteclays, examples of which include bentonites, hectorites, and colloidalmagnesium aluminum silicates. These and other suitable clay suspendingagents are preferably hydrophobically treated, and when so treated willgenerally be used in combination with a clay activator. Non-limitingexamples of suitable clay activators include propylene carbonate,ethanol, and combinations thereof. The amount of clay activator willtypically range from about 25% to about 75% by weight of the clay, moretypically from about 40% to about 60% by weight of the clay.

Liquid Carrier

The antiperspirant and deodorant compositions for use in the applicatorof the present invention comprise a liquid carrier that is a liquidunder ambient conditions, wherein the liquid carrier comprises one ormore carrier liquid combinations or combinations of carrier liquids anddissolved carrier solids provided that any such combination is in liquidform under ambient conditions.

Concentrations of the liquid carrier in the antiperspirant and deodorantcompositions will vary with the type of liquid carrier selected, thetype of suspending or thickening agent used in combination with theliquid carrier, the type of product form desired, and so forth.Preferred concentrations of the liquid carrier ranges from about 1% toabout 90%, preferably from about 10% to about 80%, more preferably fromabout 20% to about 70%, by weight of the selected antiperspirant ordeodorant composition.

The antiperspirant and deodorant compositions described herein may beformulated as aqueous or anhydrous compositions. For an aqueousformulation, the compositions may further comprise from about 10% toabout 75% by weight of water, preferably from about 10% to about 60% byweight of water, even more preferably from about 15% to about 50%, byweight of water. For an anhydrous formulation, the compositions containless than about 10%, more preferably less than about 5%, even morepreferably less than about 3%, even more preferably less than about 1%,most preferably zero percent, by weight of free or added water.

The liquid carrier comprises one or more liquid carriers suitable fortopical application to human skin. These liquid carriers include anytopically safe and effective organic, silicone containing orfluorine-containing, volatile or non-volatile, polar or non-polarcarrier liquid, provided that the resulting combination of carriermaterials form a solution or other homogenous liquid or liquiddispersion at the selected processing temperature of the composition.Processing temperatures for the antiperspirant and deodorantcompositions typically range from about 28° C. to about 250° C., moretypically from about 28° C. to about 110° C., and even more typicallyfrom about 28° C. to about 100° C.

The term “volatile” as used herein refers to those materials which havea vapor pressure as measured at 25° C. of from about 0.01 mmHg to about6 mmHg, preferably from about 0.02 mmHg to about 1.5 mmHg, and anaverage boiling point at one atmosphere of pressure (1 atm) of less thanabout 250° C., preferably less than about 235° C., at 1 atmosphere (atm)of pressure. Conversely, the term “nonvolatile” as used herein refers tothose materials which do not have a measurable vapor pressure under 1atmosphere of pressure, at about 50% relative humidity, at about 25° C.

The term “nonpolar” as used herein refers to those materials which havea solubility parameter of less than 8.0 (cal/cm³)^(0.5), preferably fromabout 5.0 (cal/cm³)^(0.5) to less than 8.0 (cal/cm³)^(0.5), morepreferably from 6.0 (cal/cm³)^(0.5) to about 7.60 (cal/cm³)^(0.5).

Solubility parameters for the liquid carriers and other materialsdescribed herein are determined by methods well known in the chemicalarts for establishing the relative polar character of a solvent or othermaterial. A description of solubility parameters and means fordetermining them are described by C. D. Vaughan, “Solubility Effects inProduct, Package, Penetration and Preservation” 103 Cosmetics andToiletries 47-69, October 1988; and C. D. Vaughan, “Using SolubilityParameters in Cosmetics Formulation”, 36 J. Soc. Cosmetic Chemists319-333, September/October, 1988, which descriptions are incorporatedherein by reference.

Nonlimiting examples of suitable silicone-containing liquid carriersinclude volatile or nonvolatile silicones, modified or organofunctionalsilicones, and combinations thereof. The volatile silicone carriers maybe cyclic, linear or branched chained silicones having the requisitevolatility defined herein. The nonvolatile silicones are preferablylinear silicones. The modified or organofunctional silicone carriersinclude polyalkylsiloxanes, polyalkyarylsiloxanes, polyestersiloxanes,polyethersiloxane copolymers, polyfluorosiloxanes, polyaminosiloxanes,and combinations thereof.

The modified silicone carriers are typically liquid under ambientconditions, and have a preferred viscosity of less than about 100,000centistokes, more preferably less than about 500 centistokes, even morepreferably from about 1 centistoke to about 50 centistokes, and mostpreferably from about 1 centistoke to about 20 centistokes. Thesemodified silicone carriers are generally known in the chemical arts,some examples of which are described in 1 Cosmetics, Science andTechnology27-104 (M. Balsam and E. Sagarin ed. 1972); U.S. Pat. No.4,202,879, issued to Shelton on May 13, 1980; U.S. Pat. No. 5,069,897,issued to Orr on Dec. 3, 1991; which descriptions are incorporatedherein by reference.

Suitable modified silicone carriers include, but are not limited to,compounds or materials such as those defined hereinabove and which aregenerally characterized as follows: silicone polyethers or siliconeglycols (such as dimethicone copolyol); silicone alkyl-linked polyethers(such as Goldschmidt EM-90 or EM-97); siloxane surfactants of apendant/rake/comb configuration, silicone surfactants of a trisiloxaneconfiguration, and silicone surfactants of an ABA/alpha-omega blockcopolymers (such as polyoxyalkylenes, polyoxyethylene or ethoxylated,polyoxyethylene/polyoxypropylene or ethoxylated/propoxylated); aromaticsubstituted silicone emollients (such as phenyl, alpha-methyl styryl,styryl, methylphenyl, alkylphenyl); silicone copolymers with otherfunctional groups include: hydrogen, alkyl, methyl, amino,trifluoropropyl, vinyl, alkoxy, arylalkyl, aryl, phenyl, styryl,polyethers, esters, carboxylics; alkylmethyl siloxanes or silicone waxes(such as hexyl, octyl, lauryl, cetyl, stearyl); nonionic functionalsiloxane copolymers with terminal groups being silanol ortrimethylsiloxy; nonionic functional siloxanes with backbone groupsbeing trisiloxane or methicone linked; nonionic silicone surfactants;tetraethoxysilane; tetramethoxysilane; hexamethoxysilicone;oxmethoxytrisiloxane; silicone emulsifiers; silicone or siloxane resins,alkyl silicone resins, polyoxyalkylene silicone resins; MQ Resins suchas Shiseido/Shin-etsu ,e.g. Japanese Patent Publication JP86143760 orfrom Walker Chem. 6MBH (described in EP722970); alkoxysiloxanes;alkoxysilanes; methicones (polymethylalkylsiloxanes); and combinationsthereof.

Nonlimiting examples of suitable modified silicone carriers for use inthe antiperspirant and deodorant compositions described herein includethe following modified silicones available from Dow Corning: DC-556Cosmetic Grade Fluid (phenyl trimethicone); DC-1784 Emulsion; DC-AFEmulsion; DC-1520-US Emulsion; DC-593 Fluid (Dimethicone [and]Trimethylsiloxysilicate); DC-3225C Fluid (Cyclomethicone [and]Dimethicone Copolyol); DC-1401 (Cyclomethicone [and] Dimethiconol);DC-5640 Powder; DC-Q2-5220 (Dimethicone Copolyol); DC Q2-5324(Dimethicone Copolyol); DC-2501 Cosmetic Wax (Dimethicone Copolyol);DC-2502 Fluid (Cetyl Dimethicone); DC-2503 Wax (Stearyl Dimethicone);DC-1731 Volatile Fluid (Caproyl Trimethicone); DC-1-3563 (Dimethiconal);DC-X2-1146A (Cylcomethicone [and] Dimethiconol); DC-7224(Trimethylsilylamodimethicone); DC-X2-1318 Fluid (Cyclomethicone [and]Vinyldimethicone); DC-QF1-3593A fluid (Trimethylsiloxysilicate) andcombinations thereof.

Other nonlimiting examples of suitable modified silicone carriersinclude the following modified silicones available from GeneralElectric: GE CF-1142 (Methylphenyl Siloxane Fluid); GE SF-1328; GESF-1188 (Dimethicone copolyol); GE SF-1188A, and combinations thereof.

Other nonlimiting examples of suitable modified silicone carriersinclude the following modified silicones available from Goldschmidt:Abil EM-90 (silicone emulsifier); Abil EM-97 (polyether siloxane);Tegomer H-Si 2111, H-Si 2311, A-Si 2120, A-Si 2320, C-Si 2141, C-Si2341, E-Si 2130, E-Si 2330, V-Si 2150, V-Si 2550, H-Si 6420, H-Si 6440,H-Si 6460 (Alpha-Omega Dimethicone Copolymers) and combinations thereof.

Other nonlimiting examples of suitable modified silicone carriersinclude the following: Masil 756 from PPG Industries (TetrabutoxypropylTrisiloxane); Silicate Cluster from Olin(Tris[tributoxysiloxy]methylsilane); silicone copolymer F-754(dimethicone copolymer from SWS Silicones); and combinations thereof.

Non-limiting examples of suitable volatile silicones for use in theantiperspirant and deodorant compositions herein are described in Toddet al., “Volatile Silicone Fluids for Cosmetics”, Cosmetics andToiletries, 91:27-32 (1976), which descriptions are incorporated hereinby reference. Preferred among these volatile silicones are the cyclicsilicones having from about 3 to about 7, more preferably from about 4to about 5, silicone atoms. Most preferably are those which conform tothe formula:

wherein n is from about 3 to about 7, preferably from about 4 to about5, most preferably 5. These volatile cyclic silicones generally have aviscosity value of less than about 10 centistokes. All viscosity valuesdescribed herein are measured or determined under ambient conditions,unless otherwise specified. Suitable volatile silicones for use hereininclude, but are not limited to, Cyclomethicone D-5 (commerciallyavailable from G. E. Silicones); Dow Corning 344, and Dow Coming 345(commercially available from Dow Corning Corp.); GE 7207, GE 7158 andSilicone Fluids SF-1202 and SF-1173 (available from General ElectricCo.); SWS-03314, SWS-03400, F-222, F-223, F-250, F-251 (available fromSWS Silicones Corp.); Volatile Silicones 7158, 7207, 7349 (availablefrom Union Carbide); Masil SF-V (available from Mazer); and combinationsthereof.

The non-volatile silicone carriers for use in the antiperspirant anddeodorant compositions described herein are preferably linear siliconeswhich include, but are not limited to, those which conform to either ofthe formulas:

wherein n is greater than or equal to 1. These linear silicone materialswill generally have viscosity values of up to about 100,000 centistoke,preferably less than about 500 centistoke, more preferably from about 1centistoke to about 200 centistoke, even more preferably from about 1centistoke to about 50 centistoke, as measured under ambient conditions.Examples of non-volatile, linear silicones suitable for use hereininclude, but are not limited to, hexamethyldisiloxane; Rhodorsil Oils70047 (available from Rhone-Poulenc); Masil SF Fluid available fromMazer; Dow Corning 200, Dow Corning 225, Dow Corning 1732, Dow Corning5732, Dow Corning 5750 (available from Dow Coming Corp.); SF-96, SF-1066and SF18(350) Silicone Fluids (available from G.E. Silicones); Velvasiland Viscasil (available from General Electric Co.); Silicone L-45,Silicone L530, Silicone L-531 (available from Union Carbide); SiloxaneF-221 and Silicone Fluid SWS-101 (available from SWS Silicones); andcombinations thereof.

The antiperspirant and deodorant compositions preferably comprise acombination of volatile and nonvolatile silicone materials, morepreferably a combination of volatile and nonvolatile silicone carrierliquids. Nonlimiting examples of suitable combinations of such siliconematerials are described in U.S. Pat. No. 5,156,834 (Beckmeyer et al.),which description is incorporated herein by reference.

Nonlimiting examples of suitable polar organic liquid carriers for usein the antiperspirant and deodorant compositions described hereininclude mono and polyhydric alcohols, fatty acids, esters of mono anddibasic carboxylic acids with mono and polyhydric alcohols,polyoxyethylenes, polyoxypropylenes, polyalkoxylates ethers of alcohols,and combinations thereof. Preferably such liquid carriers are alsowater-immiscible liquids under ambient conditions. Other suitablewater-immiscible, polar organic liquid carriers or solvents for useherein are described in Cosmetics, Science, and Technology, Vol. 1,27-104, edited by Balsam and Sagarin (1972); U.S. Pat. No. 4,202,879issued to Shelton on May 13, 1980; and U.S. Pat. No. 4,816,261 issued toLuebbe et al. on Mar. 28, 1989, which descriptions are incorporatedherein by reference.

Other suitable liquid carriers for use in the antiperspirant anddeodorant compositions described herein include anhydrous,water-miscible, polar organic liquid carriers or solvents, examples ofwhich include short chain alcohols such as ethanol, and glycol solventssuch as propylene glycol, hexylene glycol, dipropylene glycol,tripropylene glycol, and so forth. Other suitable similar solvents alsoinclude polyalkoxylated carriers such as polyethylene glycols,polyproylene glycols, combinations and derivatives thereof, and soforth. Non-limiting examples of polar solvents suitable for use hereinare described in U.S. Pat. No. 5,429,816, which description isincorporated herein by refererence. Other suitable polar solventsinclude phthalate co-solvents, benzoate co-solvents, cinnamate esters,secondary alcohols, benzyl acetate, phenyl alkane, and combinationsthereof.

Nonlimiting examples of suitable nonpolar liquid carriers for use in theantiperspirant and deodorant compositions described herein includemineral oil, petrolatum, isohexadecane, isododecane, various hydrocarbonoils such as the Isopar or Norpar series available from Exxon Corp., thePermethyl series available from Persperse, and the Soltrol seriesavailable from Phillips Chemical, and any other polar or nonpolar,water-miscible, organic carrier liquid or solvent known or otherwisesafe and effective for topical application to human skin.

Other suitable liquid carriers for use in the antiperspirant anddeodorant compositions described herein include fluorine-containingliquid carriers such as fluorochemicals including fluorosurfactants,fluorotelemers, and perfluoropolyethers, some examples of which aredescribed in Cosmetics & Toiletries, Using Fluorinated Compounds inTopical Preparations, Vol. 111, pages 47-62, (October 1996), whichdescription is incorporated herein by reference. More specific examplesof such liquid carriers include, but are not limited to,perfluoropolymethyl isopropyl ethers, perfluoropolypropylethers,acrylamide fluorinated telomer, fluorinated amide surfactants,perfluorinated thiol surfactants. Other more specific examples include,but are not limited to, the polyperfluoroisopropyl ethers available fromDupont Performance Chemicals under the trade name Fluortress® PFPE oils,and the series of fluorosurfactants available from Dupont PerformanceChemicals under the trade name Zonyl® Fluorosurfactants.

The antiperspirant compositions described herein may further comprisedimethiconol as an optional liquid carrier. Preferred concentrations ofthe dimethiconol range from about 0.1% to about 50%, more preferablyfrom about 1% to about 35%, even more preferably from about 2% to about20%, by weight of the selected antiperspirant composition. Dimethiconolssuitable for use as an optional liquid carrier include thosecorresponding to the formula:

wherein n is number having a value of zero or greater, preferably fromabout 1 to about 100, more preferably from about 1 to about 50, evenmore preferably from about 1 to about 10. Nonlimiting examples ofsuitable dimethiconols include Masil® SFR 70, Mazol® SFR 18,000, Mazol®SFR 50,000, Mazol® SFR 100, Mazol® SFR 150,000, Mazol® SFR 750, Mazol®SFR 2000, and Mazol® SFR 3500, all available from PPG/SpecialtyChemicals; Unisil SF-R available from Universal Preservative; andcombinations thereof. Other available dimethiconols include Abil® OSW12, OSW 13, Abil® OSW 15, and Abil® CK, all available from Goldschmidt;Dow Corning® 1401 Fluid, Dow Corning® Q2-1403 Fluid, Dow Corning®X2-1286 Fluid, all available from Dow Corning; Tri-Sil HGC 5000available from Tri-K Industries; and combinations thereof.

Optional Components

The antiperspirant and deodorant compositions for use in the applicatorof the present invention may further comprise one or more optionalcomponents which may modify the physical or chemical characteristics ofthe compositions or serve as additional “active” components whendeposited on the skin. The compositions may also further compriseoptional inert ingredients. Many such optional materials are known foruse in antiperspirants, deodorants or other personal care compositions,and may be used in the antiperspirant and deodorant compositionsdescribed herein, provided that such optional materials are compatiblewith the essential materials described herein, or do not otherwiseunduly impair product performance.

Nonlimiting examples of optional ingredients suitable for use in theantiperspirant and deodorant compositions described herein include pHbuffering agents; additional emollients; humectants; dyes and pigments;medicaments; emulsifiers; chelants; distributing agents; preservatives;residue masking agents; wash-off aids; and soothing agents such as aloevera, allantoin, D-panthenol, avocado oil and other vegetable oils, andlichen extract.

Rheology

One embodiment of the antiperspirant compositions described herein areantiperspirant creams which have a select rheology profile. The rheologyprofile as defined herein is a combination of select product deltastress (dyne/cm²) and static yield stress (dyne/cm²) values for theantiperspirant cream compositions. Methods for measuring or determiningeach of these essential characteristics of the rheology profile aredescribed in detail hereinafter. Rheology methodologies are carried outat 27° C., 15% relative humidity, unless otherwise specified.

1. Methodology: delta stress and static yield stress

To determine delta stress and static stress yield values for theantiperspirant cream compositions, the compositions are analyzed using aRheometrics Dynamic Stress Rheometer (available from Rheometrics Inc.,Piscatawany, N.J., U.S.A) with data collection and analysis performedusing Rhios software 4.2.2 (also available from Rheometrics Inc.,Piscatawany, N.J., U.S.A.). The rheometer is configured in a parallelplate design using a 25 mm upper plate (available as part numberLS-PELT-IP25 from Rheometrics Inc., Piscatawany, N.J., U.S.A.).Temperature control is set at 37° C. Analysis of the antiperspirantcream is performed in the “Stress Sweep: steady sweep” default testmode. Rheometer settings are initial stress (1.0 dyne/cm²), final stress(63,930 dyne/cm²), stress increment (100 dyne/cm²), and maximum time perdata point (5 seconds).

The term “static yield stress” as used herein refers to the minimumamount of stress (dyne/cm²) that must be applied to the antiperspirantcream composition to move the upper plate of the Rheometrics DynamicStress Rheometer a distance of about 4.2 micro radians, in accordancewith the analysis methods described herein. In other words, static yieldstress represents the point in a stress sweep analysis (describedherein) of a product at which point the rheometer is first capable ofmeasuring product viscosity.

The term “delta stress” as used herein is determined by subtracting thestatic yield stress from the dynamic yield stress of a composition. Thedynamic yield stress is the point at which the measured viscosity beginsto rapidly decline. This can be easily determined by finding the laststress value where the increment between stress values is 100 dynes/cm².In other words, the delta stress of the composition represents theincremental amount of stress that must be applied to the composition,beyond the static yield stress of the composition, to substantiallyliquefy the composition.

The antiperspirant cream composition is evaluated for rheologycharacteristics after the composition has been packaged in theapplicator device of the present invention. A section of the compositionis carefully removed from the applicator so that the product issubjected to minimal shear, and especially so that it is not permittedto curl or otherwise reconfigure to a shape other than that of thesection as it was removed from the composition. The section is carefullyplaced flat on the lower plate of the rheometer taking care to minimizethe application of shear stress on the section during the placement. Thearea of the placed section is at least about the size of the upper plateto assure proper contact between the two plates during testing. Theupper plate is then lowered toward the bottom plate, and positionedabout 2 mm above the lower plate, and therefore about 1 mm from theproduct section which is positioned flat on the lower plate. The upperplate is further lowered at a minimal rate toward the lower plate, andpositioned about 1.000 (+0.002) mm above the lower plate, at which pointthe product is gently positioned between and contacting each of thelower and upper plates. Excess product extending away from and aroundthe parallel positioned plates is gently removed using a spatula, andtaking care to subject the product positioned between plates to minimalor no further shear from the spatula. The solvent guard pad on therheometer is saturated with the type of liquid carrier corresponding tothat in the test product. The solvent guard is lowered over the parallelplates to prevent solvent loss from the test product that is positionedbetween the plates during analysis. The product is now ready forrheology analysis and determination of dynamic stress, static yieldstress, and delta stress.

Product samples are subjected to rheological test and evaluation inaccordance with the above described methodology. Data from the abovedescribed analysis can be plotted as viscosity (pascal-sec.) on a logscale versus linear applied stress (dyne/cm²). The initial point atwhich the instrument measures a viscosity is the static yield stress(i.e. the lowest stress at which the instrument shows a non-zeroviscosity). The dynamic yield stress is the point at which the measuredviscosity begins to rapidly decline. This can be easily determined byfinding the last stress value where the increment between stress valuesis 100 dyne/cm². The delta stress is then determined by subtracting thestatic yield stress from the dynamic yield stress.

The antiperspirant cream compositions have a static yield stress valueof at least about 4,000 dyne/cm², more preferably at least about 8,000dyne/cm², even more preferably at least about 40,000 dyne/cm². Themaximum static yield stress values for the compositions are preferablyless than about 120,000 dyne/cm², more preferably less than about 63,000dyne/cm².

The delta stress value of the antiperspirant cream compositions is fromabout 300 dyne/cm² to about 8,000 dyne/cm², preferably from about 1,000dyne/cm² to about 6,000 dyne/cm², more preferably from about 1,000dyne/cm² to about 5,000 dyne/cm². A delta stress below the minimum levelcan result in solvent syneresis during shear force delivery means,whereas a value above the recited maximum can result in nonuniformspreading of the product onto the skin, and reduced spreadability on theskin, especially on hairy areas of the skin. The delta stress values,therefore, recited herein provide for a smooth creamy product that showsminimal or no solvent syneresis, spreads uniformly over the skin, andspreads especially well over and through hairy areas of the skin.

Skin Care Compositions

Another suitable category of substances believed suitable for use withthe applicators of the present invention is the class of compositionsgenerally referred to as skin care compositions. Such compositionsinclude those intended to treat or modify human skin in terms ofstructure, condition, or appearance. By way of example only, and not tobe interpreted as limiting, an area of current interest in the skin carearea relates to compositions designed to address issues associated withthe onset of skin wrinkles. Representative compositions in this areainclude salicylic acid technologies, such as those disclosed incommonly-assigned, published PCT applications WO 92/09737 and WO92/09739, both published Jun. 10, 1993, and WO 92/08741, published Apr.29, 1993. Another area of current interest is skin care compositionscontaining niacinamide, such as those disclosed in published PCTapplications WO 96/17672, published May 15, 1997, and WO 97/06680,published Oct. 30, 1997. All of these publications are herebyincorporated herein by reference. Other suitable compositions includethose disclosed in commonly-assigned U.S. Pat. Nos. 5,720,961,5,707,635, 5,703,026, 5,700,451, 5,683,706, 5,674,509, and 5,665,364,the disclosures of which are hereby incorporated herein by reference.

Hair Care Compositions

The applicator of the present invention can also be used for topicalapplication of hair care products to the hair. Hair care products whichmay be applied include shampoos, rinse-off conditioners, leave-onconditioning products, colorants, hair styling sprays, gels, andmousses.

Shampoos, used for cleansing hair, generally comprise one or moresurfactants, thickeners or suspending agents, perftumes, and otionallyconditioning or styling agents. Typical shampoos are disclosed in U.S.Reissue Pat. No. 34,584, Grote et al., issued Apr. 12, 1994; U.S. Pat.No. 5,756,436, Royce et al., May 26, 1998; U.S. Pat. No. 5,648,323,Coffindaffer et al., issued Jul. 15, 1997; U.S. Pat. No. 5,612,301,Inman, issued Mar. 18, 1997; U.S. Pat. No. 5,573,709, Wells, issued Nov.12, 1996; U.S. Pat. No. 5,151,210, Steuri et al., issued Sep. 29, 1992;U.S. Pat. No. 4,704,272, Oh, issued Nov. 3, 1987; U.S. Pat. No.4,705,681, Maes et al., issued Nov. 10, 1987; U.S. Pat. No. 4,387,090,Bolich Jr. Et al., issued Jun. 7, 1983; U.S. Pat. No. 4,379,753, BolichJr., issued Apr. 12, 1983; and U.S. Pat. No. 4,345,080, Bolich Jr. etal., issued Aug. 17, 1982.

Hair conditioning products are generally used to apply conditioningagents to the hair after shampooing to improve detangling and/or providesoft hair feel. Typical rinse-off conditioners are disclosed in U.S.Pat. No. 5,667,771, Carballada et al., issued Sep. 16, 1997; U.S. Pat.No. 5,482,703, Pings, issued Jan. 9, 1996; U.S. Pat. No. 5,106,609,Bolich Jr. et al., issued Apr. 21, 1992; U.S. Pat. No. 5,104,646, BolichJr. et al., issued Apr. 14, 1992; and U.S. Pat. No. 4,387,090, BolichJr. issued Jun. 7, 1983. Typical leave-on conditioning products aredisclosed in U.S. Pat. No. 5,674,478, Dodd et al, Oct. 7, 1997.

Hair styling products, such as aerosol and non-aerosol hair sprays,mousses, and gels are disclosed in U.S. Pat. No. 5,750,122, Evans etal., May 12, 1998; U.S. Pat. No. 5,730,966, Torgerson et al., Mar. 24,1998; U.S. Pat. No. 5,674,478, Dodd et al, Oct. 7, 1997; U.S. Pat. No.5,658,557, Bolich Jr. et al., issued Aug. 19, 1997; U.S. Pat. No.5,166,276, Hayama et al., issued Nov. 24, 1992; and U.S. Pat. No.5,753,216, Leitch et al., issued May 19, 1998.

Hair coloring products have been generally disclosed in U.S. Pat. No.5,679,114, Haning et al., issued Oct. 21, 1997; U.S. Pat. No. 5,597,386,Igarashi et al., issued Jan. 8, 1997; U.S. Pat. No. 5,435,810, Prota etal, issued Jul. 25, 1995; U.S. Pat. No. 5,356,439, Schultz et al.,issued Oct. 18, 1994; U.S. Pat. No. 4,183,366, Bartuska et al., issuedJan. 15, 1980; and U.S. Pat. No. 4,200,432, Kalopissis et al., issuedApr. 29, 1980.

Other Substances

While much of the foregoing discussion has focused upon particularsubstances such as antiperspirant compositions which have provensuitable for use with applicators according to the present invention, itshould be understood that the principles of the present invention arebelieved to apply to other applicator/substance combinations wherein theapplicator is designed to account for the particular characteristics ofthe substance and the nature of the application environment. Forexample, it is believed that other compositions such as sunscreens,cooking products such as fats, oils, and shortenings, waxes such as shoepolishes and the like, and other substances may be suitable for use withapplicators as described herein.

In accordance with the present invention, the substance utilized incombination with the deformable material exhibits a selection ofphysical properties which enable it to be dispensed from its protectedorientation within the three-dimensional structure and applied to thetarget surface. Such dispensation may be partial, or substantially ortotally complete in nature.

To facilitate such dispensing, substance properties which are believedto be important include the relative affinity of the substance for thetarget surface versus that for the deformable material and the apparentviscosity or flowability of the substance after activation of thethree-dimensional structure. It is presently believed that the substanceshould preferentially adhere to the target surface to a greater extentthan to the deformable material and/or to a greater extent than forother portions of the substance itself. Said differently, the substancehas a greater affinity for the target surface than for itself and/or forthe deformable sheet material.

Substances may inherently possess viscosity and flow characteristicswhich permit their liberation from their protected location within thesheet material or may require viscosity modification to permitliberation and dispersal. Viscosity modification may be obtained by theselection of substances which undergo a change in viscosity in responseto the mode of activation selected. For example, for a mechanicalactivation such as a compressive force it may be desirable, andpreferably, to employ substances which are commonly referred to as“shear-thinning” (pseudoplastic) substances. Examples of such substancesinclude polymer solutions, many gels and pastes such as dentrifice andbody creams, paints, gelled wood stains, etc. Other materials behave asshear-thinning materials only after a certain threshold shear (yieldstress) is reached or exceeded. Such materials are commonly referred toas Bingham plastic materials, and one common example of a substanceexhibiting such behavior is the type of condiment known as ketchup.

Some of the factors believed to influence the adhesion or affinity ofthe substance for the target surface include: electrostatic orelectrical charges; chemical bonds via hydrogen bonding, covalentbonding, ionic bonding, partial ionic bonds (partial dipolarattraction), van der Walls forces, osmotic forces, etc.; capillarypressure (suction); adsorption; absorption; vacuum/suction; etc. Otherimportant factors include the wettability of the substance upon thetarget surface, as reflected by the contact angle of the substance onthe target surface.

To facilitate spreading or dispersal of the substance upon the targetsurface, particularly to counteract the tendency of the substance toremain in a localized distribution pattern given the localizedorientation upon the deformable substance, it is presently preferred toutilize substances which are tailored so as to be wettable on the targetsurface. Other factors which may aid in dispersion or distribution ofthe substance upon the target surface include the use of substanceswhich exhibit a shear-thinning behavior, as well as mechanical spreadingaction provided by the user of the composite sheet material to impart alateral mechanical motion after activation but prior to removal of thedeformable material from the target surface. Such lateral mechanicalaction may also provide additional interaction with the substance suchas for shear-thinning substances and may provide additional benefitssuch as lathering, foam generation, scrubbing/abrasive action, etc.

Successful dispersal occurs when a portion of the deposited or dispensedsubstance subsequently coats a portion of the target surface where thesubstance was not originally deposited. Upon removal of the sheetmaterial from the target surface, at least some of the substance remainslocated on the target surface, preferably in a substantially-uniformfashion.

As discussed above, a wide variety of substances may be selected for usein accordance with the principles of the present invention.Representative substances for illustrative purposes include cleansingagents such as soaps and detergents, emollients such as lotions,medicinal agents such as ointments, anti-inflammatory creams, etc.,health and beauty care products, including antiperspirants, deodorants,cosmetics, fragrances, and the like. Other more diverse applications forsuch a sheet material include applicators for automotive and householdproducts such as lubricants, colorants, protectants such as oils andwaxes, adhesives, preservatives, and the like, as well as food-orientedapplications such as condiments (mustard, ketchup, etc.).

Multiple substances may also be employed which are not only protectedfrom inadvertent contact but segregated from one another initially (onthe same face of, or on opposing faces of, the sheet material) and becommingled during the activation process or during subsequent dispensingand/or dispersion operations. Multiple diverse substances (ie:substances having different properties) may be included in either thesame reservoir 50 or separate reservoirs 50.” Such an arrangement may beparticularly usefuil for substances which beneficially interact with oneanother (e.g., co-dispensing epoxies, catalyzed reactions, etc.) toprovide additional fuinctionality with each other and/or with the targetsurface. It may also be desirable to provide for progressive orsequential substance delivery by tailoring the geometry of theapplicator or substance properties to provide for initial applicationfollowed by additional progressive dispensing with the passage of time,increased pressure, etc.

3. Methods of Manufacture.

The applicators of the present invention may be manufactured in anymanner suitable for the intended geometry and intended materials andsubstances involved. By way of example, for the presently preferred foammaterials articulated above, the configuration of FIG. 1 may bemanufactured by forming the plurality of apertures and reservoirs viathermal embossing with a heated die to the desired depth, then eitherinjecting the substance into the reservoirs or flooding the substanceinto/onto the applicator and doctoring off the excess substance. A labelor seal is then applied over the delivery zone and secured by thermal oradhesive means. The applicator may then be die cut to the final shape,or alternatively the die cutting step may be accomplished at the sametime as the formation of the reservoirs, or any other suitablearrangement of steps. The substance may be heated or otherwise madeflowable for such a process if necessary.

For an embodiment with a single reservoir such as that of FIG. 4, theapplication surface may be similarly manufactured, the backsheet may beperipherally joined by thermal or other means, and the substance may beinjected into the reservoir from a single source or multiple sources ifdesired.

While particular embodiments of the present invention have beenillustrated and described, it will be obvious to those skilled in theart that various changes and modifications may be made without departingfrom the spirit and scope of the invention, and it is intended to coverin the appended claims all such modifications that are within the scopeof tile invention.

What is claimed is:
 1. An applicator for applying and distributing asubstance onto a target surface, said applicator comprising: (a) asubstantially planar sheet of compressible, conformable material havingopposed first and second surfaces and an interior region between saidfirst and second surfaces, said sheet of material having a thicknessbetween said first and second surfaces which decreases when said sheetof material is subjected to an externally-applied force in a directionsubstantially normal to said first surface, said material adapted toglide across the target surface to thereby expel the substance onto thetarget surface; (b) at least one discrete reservoir extending inwardlyof said first surface into the interior of said sheet of material; (c) asubstance at least partially filling said reservoir; and (d) at leastone discrete aperture formed in said first surface, said aperture beingin fluid communication with said reservoir; whereby compression of saidsheet of material via an externally-applied force substantially normalto said first surface expresses said product from said aperture andtranslational motion of said first surface relative to a target surfaceapplies and distributes said product onto said target surface; whereinsaid applicator is made from all conformable elements.
 2. The applicatorof claim 1, wherein said applicator includes a plurality of aperturesforming a delivery zone adjacent to one end of said applicator.
 3. Theapplicator of claim 1, wherein said substance fills said reservoir to alevel at least equal to said first surface.
 4. The applicator of claim1, wherein said reservoir defines an interior volume which decreaseswhen said thickness is reduced by an externally-applied force.
 5. Theapplicator of claim 1, wherein said applicator includes a plurality ofapertures.
 6. The applicator of claim 1, wherein said applicatorincludes a plurality of reservoirs.
 7. The applicator of claim 1,wherein said applicator includes a plurality of apertures and acorresponding plurality of reservoirs, each of said apertures being influid communication with one of said reservoirs.
 8. The applicator ofclaim 1, wherein said reservoir extends inwardly of said first surfaceinto the interior of said sheet of material but does not penetrate saidsecond surface.
 9. The applicator of claim 1, wherein said reservoirextends inwardly of said first surface into the interior of said sheetof material a distance which is less than said thickness.
 10. Theapplicator of claim 1, wherein said sheet material is resilient incompression.
 11. The applicator of claim 1, wherein said sheet materialis resilient in bending.
 12. The applicator of claim 1, wherein saidsheet material comprises a closed-cell foam material.
 13. The applicatorof claim 1, wherein said applicator includes a removable cover sheet forenclosing said aperture prior to use.
 14. The applicator of claim 1,wherein said applicator includes a plurality of reservoirs and acorresponding plurality of apertures, and wherein said reservoirsinclude multiple diverse substances.
 15. A method of making anapplicator for applying and distributing a substance onto a targetsurface, said method comprising the steps of: (a) providing asubstantially planar sheet of compressible, conformable material havingopposed first and second surfaces and an interior region between saidfirst and second surfaces, said sheet of material having a thicknessbetween said first and second surfaces which decreases when said sheetof material is subjected to an externally-applied force in a directionsubstantially normal to said first surface, said material adapted toglide across the target surface to thereby expel the substance onto thetarget surface; (b) forming at least one discrete reservoir extendinginwardly of said first surface into the interior of said sheet ofmaterial; (c) at least partially filling said reservoir with asubstance; and (d) forming at least one discrete aperture in said firstsurface, said aperture being in fluid communication with said reservoir;wherein said applicator is made from all conformable elements.
 16. Themethod of claim 15, wherein said reservoir is formed by thermalembossing.
 17. The method of claim 15, wherein said substance isinjected into said reservoir.
 18. The applicator of claim 1, whereinsaid reservoir is a slot type reservoir.
 19. The applicator of claim 1,wherein said reservoir is an aperture-channel type reservoir.
 20. Theapplicator of claim 1, wherein said reservoir is an aperture-channeltype reservoir positioned diagonally at a 45° angle.
 21. The applicatorof claim 1, wherein said reservoir has an aspect ratio of about 5 orbelow.
 22. An applicator for applying and distributing a substance ontoa target surface, said applicator comprising: (a) a substantially planarsheet of compressible, conformable material having opposed first andsecond surfaces and an interior region between said first and secondsurfaces, said sheet of material having a thickness between said firstand second surfaces which decreases when said sheet of material issubjected to an externally-applied force in a direction substantiallynormal to said first surface, said material adapted to glide across thetarget surface to thereby expel the substance onto the target surface;(b) at least one discrete reservoir; (c) a substance at least partiallyfilling said reservoir; and (d) at least one discrete aperture whichfully penetrates said first and second surfaces, said aperture being influid communication with said reservoir; (e) a backing sheetperipherally joined to said second surface, wherein said reservoir isformed between said second surface and said backing sheet; wherebycompression of said sheet of material via an externally-applied forcesubstantially normal to said first surface expresses said product fromsaid aperture and translational motion of said first surface relative toa target surface applies and distributes said product onto said targetsurface; wherein said applicator is made from all conformable elements.23. An applicator for applying and distributing a substance onto atarget surface, said applicator comprising: (a) a substantially planarsheet of compressible, conformable material having opposed first andsecond surfaces and an interior region between said first and secondsurfaces, said sheet of material having a thickness between said firstand second surfaces which decreases when said sheet of material issubjected to an externally-applied force in a direction substantiallynormal to said first surface, said market adapted to glide across thetarget surface to thereby expel the substance onto the target surface;(b) at least one discrete reservoir; (c) a substance at least partiallyfilling said reservoir; and (d) at least one discrete aperture whichfully penetrates said first and second surfaces, said aperture being influid communication with said reservoir; (e) a backing sheetperipherally joined to said second surface, wherein said reservoir isformed between said second surface and said backing sheet; wherebycompression of said sheet of material via an externally-applied forcesubstantially normal to said first surface expresses said product fromsaid aperture and translational motion of said first surface relative toa target surface applies and distributes said product onto said targetsurface; wherein said applicator does not contain a rigid member. 24.The applicator of claim 1, wherein said substance comprises: (a) fromabout 0.1 to about 35 wt % a thickening agent selected from the groupconsisting of fatty alcohols, esters of fatty alcohols, fatty acids,hydroxy fatty acids, esters and amides of fatty acids or hydroxy fattyacids, ethers of fatty acids, ethoxylated fatty alcohols, ethoxylatedfatty acids, waxes, cholesteric materials, dibenzylidene alditols,lanolinolic materials, other amide and polyamide gellants, andcorresponding salts thereof, and mixtures thereof; and (b) from about 1%to about 90 wt % of a liquid carrier selected from the group consistingof silicones, modified silicones, mineral oil, petrolatum, hydrocarbonoils, and mixtures thereof.